JP2012026055A - Fiber structure and fiber product using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide: a fiber structure including a main fiber and a binder component and formed by fixing the main fiber with the binder component, the fiber structure being excellent in durability such as physical properties, a shape; and a fiber product formed by using the same.SOLUTION: A fiber structure is provided, including a main fiber and a binder component, and formed by fixing the main fiber with the binder component. The fiber structure has the flatness of 2.0 or less and two or more openings having an aperture angle of less than 120°, in a single fiber cross section of the main fiber.

Description

  The present invention relates to a fiber structure comprising a main fiber and a binder component, wherein the main fiber is fixed by the binder component, and has excellent durability such as physical properties and shape, and the fiber structure. The present invention relates to a textile product using

Conventionally, a fiber structure in which main fibers made of short fibers are fixed with a binder component is used in applications such as vehicle materials, cushion materials, sound absorbing materials, filter materials, and the like (for example, Patent Document 1 and Patent Document 2) .
However, such a fiber structure has not yet been satisfactory in terms of physical properties and durability of the shape.

JP 2001-226863 A JP-A-4-240219

  The present invention relates to a fiber structure comprising a main fiber and a binder component, wherein the main fiber is fixed by the binder component, and has excellent durability such as physical properties and shape, and the fiber structure. It is providing the textiles which use this.

  As a result of diligent study to achieve the above-mentioned problems, the present inventor makes it easy to form a fixing point due to the binder component by setting the single fiber cross-sectional shape of the main fiber constituting the fiber structure to a specific shape. As a result, the present inventors have found that the durability such as the physical properties and shape of the fiber structure is improved, and have made further studies to complete the present invention.

Thus, according to the present invention, “a fiber structure including a main fiber and a binder component, and the main fiber is fixed by a binder component, and in a single fiber cross-sectional shape of the main fiber, There is provided a fiber structure characterized by having two or more openings having a flatness to be defined of 2.0 or less and an opening angle of less than 120 degrees.
Flatness = (B / A) × 100
A: The longest length in the fiber cross section B: The length in the direction perpendicular to the length direction of A in the fiber cross section

In that case, it is preferable to have 5 or more of the said opening part in the single fiber cross-sectional shape of the said main fiber. The main fiber is preferably a hollow fiber. Moreover, in the single fiber cross-sectional shape of the said main fiber, it is preferable that the fiber filling rate defined by a following formula is in the range of 30 to 80%.
Fiber filling rate (%) = (C / D) × 100
C: area of the fiber cross section D: circumscribed circle area of the fiber cross section

  Moreover, it is preferable that the single fiber diameter of the said main fiber exists in the range of 10-50 micrometers. Moreover, it is preferable that the fiber length of the said main fiber exists in the range of 30-100 mm. Moreover, it is preferable that the said binder component is a core-sheath-type binder fiber. The binder component is preferably a non-fiber resin binder.

In the fiber structure of the present invention, the density of the fiber structure is preferably 0.06 g / cm ³ or less. Moreover, it is preferable that the fabric weight of a fiber structure exists in the range of 50-5000 g / m < ² >. Moreover, it is preferable that the thickness of a fiber structure exists in the range of 1-200 mm.

  Moreover, according to the present invention, from the vehicle material, cushion material, sound absorbing material, bedding, furniture, clothing, filter material, sanitary material, building material, civil engineering material, and agricultural material, comprising the above fiber structure. Any textile product selected from the group is provided.

  According to the present invention, a fiber structure comprising a main fiber and a binder component, wherein the main fiber is fixed by the binder component, the fiber structure having excellent durability such as physical properties and shape, and the fiber A fiber product using the structure is provided.

It is a schematic diagram for demonstrating an opening part.

First, in the single fiber cross-sectional shape of the main fiber contained in the fiber structure of the present invention, it is important that the flatness is 2.0 or less (preferably 1 to 1.2). When the flatness is larger than 2.0, it is difficult to form voids between the fibers, so that the fluidity of the binder component is lowered and the fixing point due to the binder component is hardly formed, which is not preferable. Furthermore, if the flatness is greater than 2.0, the dispersibility of the fibers may be reduced, thereby reducing the bulkiness of the fiber structure. However, the flatness is defined by the following formula.
Flatness = (B / A) × 100
A: The longest length in the fiber cross section B: The length in the direction perpendicular to the length direction of A in the fiber cross section

  Further, in the single fiber cross-sectional shape of the main fiber, two or more openings having an opening angle of less than 120 degrees (preferably 5 or more, more preferably 5 to 25, and further preferably 12 to 20). It is important to have. When the number of the openings is less than 2, it is not preferable because the fluidity of the binder component is lowered and a fixing point due to the binder component is hardly formed. Furthermore, when the number of openings is less than 2, the fiber dispersibility may decrease, and the bulk of the fiber structure may decrease. However, the opening part as used in the field of this invention is a location shown in FIG.

In particular, in the single fiber cross-sectional shape of the main fiber, when the fiber filling rate defined by the following formula is within the range of 30 to 80%, the fluidity of the binder component is improved and the fixing point due to the binder component is easily formed. preferable.
Fiber filling rate (%) = (C / D) × 100
C: area of the fiber cross section D: circumscribed circle area of the fiber cross section

  Specific examples of the single fiber cross-sectional shape include a ten cross section, an H cross section, a T cross section, a Y cross section, and an atypical multi-fin cross section. Especially, the hollow fiber which has a hollow part in single fiber cross-sectional shape is preferable. In particular, an atypical multi-fin cross-section having a hollow portion in a single fiber cross-sectional shape is preferable because the fluidity of the binder component is improved and a fixing point due to the binder component is easily formed.

  In the main fiber, the single fiber diameter is preferably in the range of 10 to 50 μm (more preferably 20 to 30 μm). If the fiber diameter is less than 10 μm, it may be difficult to form a fixing point. On the other hand, when the fiber diameter is larger than 50 μm, the processability such as the card process in producing the fiber structure may be unstable. The single fiber fineness of the single fiber is preferably in the range of 0.1 to 17 dtex.

  In the main fiber, the fiber may be long fiber, but short fiber is preferable in order to improve the fluidity of the binder component by increasing the dispersibility of the fiber and to easily form the fixing point by the binder component. At that time, the fiber length is preferably within a range of 30 to 100 mm. If the fiber length is less than 30 mm, card processability such as a fiber opening process may become difficult. On the other hand, if the fiber length is longer than 100 mm, a fiber structure having a uniform texture may not be obtained.

  In addition, it is preferable that crimping is imparted to the main fiber because the fluidity of the binder component is improved and a fixing point due to the binder component is easily formed. At that time, as a method for imparting crimps, a spiral crimp is applied using a composite fiber obtained by laminating polymers having different heat shrinkage rates to a side-by-side type, or a spiral crimp is applied by anisotropic cooling, Alternatively, various methods such as imparting mechanical crimping by an ordinary indentation crimper method such that the number of crimps is 3 to 40 pieces / 2.54 cm (preferably 7 to 15 pieces / 2.54 cm) may be used. However, it is optimal to impart mechanical crimping from the viewpoints of bulkiness and manufacturing cost.

  The type of polymer that forms the main fiber is not particularly limited, and may be a normal fiber-forming polymer such as polyester, polyamide, or polyolefin. Of these, polyesters such as polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polylactic acid, and stereocomplex polylactic acid, and copolyesters obtained by copolymerizing the third component are preferred. Examples of such polyester include material-recycled or chemical-recycled polyester, and polyethylene terephthalate using a monomer component obtained by using biomass, that is, a biological material as a raw material, described in JP-A-2009-091694. May be. Furthermore, the polyester obtained using the catalyst containing the specific phosphorus compound and titanium compound which are described in Unexamined-Japanese-Patent No. 2004-270097 and 2004-21268 may be sufficient. In the polymer, a fine pore forming agent, a cationic dye dyeing agent, an anti-coloring agent, a heat stabilizer, a fluorescent whitening agent, a matting agent, a coloring agent may be added as necessary within the range not impairing the object of the present invention. 1 type, or 2 or more types of an agent, a hygroscopic agent, and inorganic fine particles may be contained.

  Further, in the main fiber, one or more selected from the group consisting of silicone resin, oil agent, antibacterial agent, insect repellent, water repellent agent, hygroscopic agent, antistatic agent, flame retardant, negative ion generator and deodorant. It is preferable that these agents adhere to the fiber surface because these agents do not easily fall off, and the functions of these agents can be expressed with good durability. The oil agent includes a smoothing agent such as fatty acid ester, polyhydric alcohol ester, ether ester, polyether, silicone, mineral oil, antistatic agent, surfactant, bundling agent, rust inhibitor, preservative, and antioxidant. An agent may be added.

In the fiber structure of the present invention, the main fiber is fixed by a binder component. In that case, as a binder component, a binder fiber may be sufficient and a non-fiber-type resin binder (for example, powdery chemical binder) may be sufficient. Of these, a core-sheath binder fiber is preferable in obtaining a strong fixing point.
As such a sheath-core type binder fiber, a polymer having a melting point lower by 40 ° C. or more than the polymer forming the main fiber is arranged on the surface as a heat fusion component.

  Here, examples of the polymer arranged as the heat fusion component include polyurethane elastomers, polyester elastomers, inelastic polyester polymers and copolymers thereof, polyolefin polymers and copolymers thereof, polyvinyl alcohol polymers, and the like. be able to.

  Among these, polyurethane elastomers include low melting point polyols having a molecular weight of about 500 to 6,000, such as dihydroxy polyether, dihydroxy polyester, dihydroxy polycarbonate, dihydroxy polyester amide, and the like, and organic diisocyanates having a molecular weight of 500 or less, such as p, p. '-Diphenyl methane diisocyanate, tolylene diisocyanate, isophorone diisocyanate hydrogenated diphenyl methane isocyanate, xylylene isocyanate, 2,6-diisocyanate methyl caproate, hexamethylene diisocyanate and the like, and chain extenders having a molecular weight of 500 or less, such as glycol It is a polymer obtained by reaction with amino alcohol or triol.

  Among these polymers, particularly preferred is a polyurethane using polytetramethylene glycol, poly-ε-caprolactam or polybutylene adipate as a polyol. Examples of the organic diisocyanate in this case include p, p'-bishydroxyethoxybenzene and 1,4-butanediol.

  Polyester elastomers include polyether ester copolymers obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, and more specifically, terephthalic acid, isophthalic acid, phthalate. Alicyclic dicarboxylic acids such as acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4′-dicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, succinic acid, oxalic acid , At least one dicarboxylic acid selected from aliphatic dicarboxylic acids such as adipic acid, sebacic acid, dodecanedioic acid and dimer acid, or ester-forming derivatives thereof, 1,4-butanediol, ethylene glycol trimethylene glycol , Tetramethylene glycol Aliphatic diols such as pentamethylene glycol, hexamethylene glycol neopentyl glycol, decamethylene glycol, or alicyclic diols such as 1,1-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, tricyclodecane methanol, or the like At least one diol component selected from ester-forming derivatives and the like, and polyethylene glycol, poly (1,2- and 1,3-polypropylene oxide) glycol, poly (tetra Methylene oxide) glycol, a copolymer of ethylene oxide and propylene oxide, a copolymer of ethylene oxide and tetrahydrofuran, and the like. It can be mentioned terpolymer.

  In particular, from the viewpoint of adhesiveness, temperature characteristics, and strength, block copolymer polyether esters having polybutylene terephthalate as a hard component and polyoxybutylene glycol as a soft segment are preferable. In this case, the polyester portion constituting the hard segment is polybutylene terephthalate in which the main acid component is terephthalic acid and the main diol component is a butylene glycol component. Of course, a part of this acid component (usually 30 mol% or less) may be substituted with another dicarboxylic acid component or an oxycarboxylic acid component, and similarly a part of the glycol component (usually 30 mol% or less). May be substituted with a dioxy component other than the butylene glycol component. Further, the polyether portion constituting the soft segment may be a polyether substituted with a dioxy component other than butylene glycol.

Copolyester polymers include aliphatic dicarboxylic acids such as adipic acid and sebacic acid, aromatic dicarboxylic acids such as phthalic acid, isophthalic acid and naphthalenedicarboxylic acid and / or fats such as hexahydroterephthalic acid and hexahydroisophthalic acid. A co-polymer containing a predetermined number of cyclic dicarboxylic acids and aliphatic or alicyclic diols such as diethylene glycol, polyethylene glycol, propylene glycol, and paraxylene glycol, with addition of oxyacids such as parahydroxybenzoic acid as desired. Polymerized esters and the like can be mentioned. For example, polyesters obtained by adding and copolymerizing isophthalic acid and 1,6-hexanediol in terephthalic acid and ethylene glycol can be used.
Examples of the polyolefin-based polymer include low-density polyethylene, high-density polyethylene, polypropylene, and modified products thereof.

In the core-sheath binder fiber, the above-mentioned polyester is preferably exemplified as the counterpart component of the heat-sealing component. In that case, it is preferable that the heat fusion component occupies at least a half of the surface area. The weight ratio is suitably in the range of 30/70 to 70/30 in terms of the composite ratio of the heat fusion component and the polyester. Although it does not specifically limit as a form of a core-sheath-type binder fiber, It is important that a heat-fusion component and polyester are core-sheath types. In this core-sheath-type binder fiber, polyester serves as a core part and the heat fusion component serves as a sheath part, but this core part may be concentric or eccentric. From the viewpoint of adhesion to the main fiber and processability (dispersibility, etc.) in the papermaking process, it is more preferable to dispose polyester in the core and dispose low-melting polyester in the sheath.
In the above-mentioned polymer, various stabilizers, ultraviolet absorbers, thickening and branching agents, matting agents, colorants and various other improving agents may be blended as necessary.

  In the core-sheath binder fiber, the single fiber diameter is preferably in the range of 10 to 50 μm (more preferably 20 to 30 μm). If the fiber diameter is less than 10 μm, it may be difficult to form a fixing point. On the other hand, when the fiber diameter is larger than 50 μm, the processability such as the card process in producing the fiber structure may be unstable. The single fiber fineness of the single fiber is preferably in the range of 1 to 25 dtex.

  Moreover, in the said core-sheath-type binder fiber, it is preferable that it is in the range of 30-100 mm as fiber length. If the fiber length is less than 30 mm, card processability such as a fiber opening process may become difficult. On the other hand, if the fiber length is longer than 100 mm, a fiber structure having a uniform texture may not be obtained.

  Moreover, it is preferable that the crimp is provided in the said core-sheath-type binder fiber. At that time, as a method for imparting crimps, a spiral crimp is applied using a composite fiber obtained by laminating polymers having different heat shrinkage rates to a side-by-side type, or a spiral crimp is applied by anisotropic cooling, Alternatively, various methods such as imparting mechanical crimping by an ordinary indentation crimper method such that the number of crimps is 3 to 40 pieces / 2.54 cm (preferably 7 to 15 pieces / 2.54 cm) may be used. However, it is optimal to impart mechanical crimping from the viewpoints of bulkiness and manufacturing cost.

  In the fiber structure of the present invention, the main fiber is fixed by a binder component. Here, the main fiber is preferably contained in an amount of 30% by weight or more (more preferably 45 to 75% by weight) relative to the weight of the fiber structure. When the content of the main fiber is less than 30% by weight, the fluidity of the binder component is lowered, and it is difficult to form a fixing point due to the binder component. In this case, when other fibers are included in the fiber structure, the other fibers include natural fibers such as cotton, semi-synthetic fibers such as rayon, and synthetic fibers such as polyester fibers having other cross-sectional shapes, The passability of the process is good and preferable.

  The fiber structure of the present invention can be produced, for example, by the following production method. That is, as described above, the main fiber and the core-sheath type binder fiber (or non-fiber type resin binder) are mixed and spun as a uniform web with a roller card, and then laminated as necessary, followed by heat treatment. By applying, the main fiber is fixed by the binder component. At that time, the fiber may be heat treated while being folded into an accordion shape to form a fixing point by heat fusion, thereby forming a fiber structure in which the constituent fibers are arranged in the thickness direction of the fiber structure.

In the fiber structure thus obtained, the density of the fiber structure is preferably 0.06 g / cm ³ or less (more preferably 0.03 to 0.06 g / cm ³ ). Further, it is preferable that the basis weight of the fibrous structure 50~5000g / ^{m 2} (more preferably 1000~3500g / ^{m 2)} is in the range of. When the basis weight is smaller than 50 g / m ² , the strength of the fiber structure may be lowered. On the other hand, if the basis weight exceeds 5000 g / m ² , there is a risk that the hot air will be poor and the heat treatment will be insufficient during the heat treatment. The thickness of the fiber structure is preferably in the range of 1 to 200 mm (more preferably 5 to 100 mm).
The fiber structure may be added with known functional processing such as water repellent processing, flameproof processing, flame retardant processing, and negative ion generation processing.

  Such a fiber structure contains the main fiber having the single fiber cross-sectional shape as described above, so that the fluidity of the binder component is improved and the fixing point due to the binder component is easily formed. As a result, durability such as physical properties and shape of the fiber structure is improved.

Next, the textile product of the present invention is a vehicle material, cushion material, sound absorbing material, bedding, furniture, clothing, filter material, sanitary material, building material, civil engineering material, and agriculture comprising the above-described fiber structure. Any textile product selected from the group consisting of materials.
Since such a fiber product includes the above-described fiber structure, it is excellent in durability such as physical properties and shape. Needless to say, the fiber structure can be used for other fiber products.

Next, although the Example and comparative example of this invention are explained in full detail, this invention is not limited by these. In addition, each measurement item in an Example was measured with the following method.
(1) Melting point Using a differential thermal analyzer 990 manufactured by Du Pont, measured at a temperature increase of 20 ° C./min, and obtained a melting peak. If the melting temperature is not clearly observed, the melting point is the temperature at which the polymer softens and starts to flow (softening point) using a trace melting point measuring device (manufactured by Yanagimoto Seisakusho). In addition, the average value was calculated | required by n number 5.
(2) Number of crimps The number of crimps was measured by the method described in JIS L 1015 7.12. In addition, the average value was calculated | required by n number 5.
(3) Flatness After 20 main fibers were extracted and observed by SEM, the average value was calculated by the following formula.
Flatness = (B / A) × 100
A: The longest length in the fiber cross section B: The length in the direction perpendicular to the length direction of A in the fiber cross section (4) Fiber filling rate (%) = (C / D) × 100
C: area of the fiber cross section D: circumscribed circle area of the fiber cross section (5) hardness (elasticity)
It was measured by 25% compression hardness according to JIS-K6400.
(6) Repeated compression residual strain (durability)
It was measured by the method described in JIS-K6400. If it is 6.5% or less, it is considered good.
(7) Thickness Thickness (mm) was measured according to JISL1096.
(8) Number of openings having an opening angle of less than 120 degrees After one main fiber was extracted and subjected to SEM observation, the number of openings having an opening angle of less than 120 degrees was counted.

[Examples 1-7, Comparative Examples 1-5]
Using a polytrimethylene terephthalate having an intrinsic viscosity of 0.85 and a melting point of 225 ° C., changing the die appropriately, melt spinning, and drawing, the single fiber fineness having a single fiber cross-sectional shape as shown in Table 1 A main fiber of 3.3 dtex (fiber length 51 mm, number of crimps 9 / 2.54 cm) was obtained.

  On the other hand, a core-sheath binder fiber (single fiber fineness 4.4 dtex, fiber length 51 mm, number of crimps 9 / 2.54 cm, single fiber cross-sectional shape: round cross section) manufactured by Teijin Fibers Ltd. was prepared. This core-sheath binder fiber is a copolymer polyester having a melting point of 110 ° C. (an acid component obtained by mixing terephthalic acid and isophthalic acid at 60/40 (mol%), ethylene glycol and diethylene glycol 85/15 ( Diol component mixed at a mol%)) is disposed in the sheath component, and ordinary polyethylene terephthalate is disposed in the core component.

Next, after blending the main fiber and the core-sheath type binder fiber at a blend ratio shown in Table 2, a uniform web was obtained using a roller card. The web was weighed and heat-treated using a hot air circulation dryer (160 ° C. × 10 minutes) to obtain a fiber structure.
Table 1 shows the main fibers used, and Table 2 shows the physical properties of the obtained fiber structure.

  According to the present invention, a fiber structure comprising a main fiber and a binder component, wherein the main fiber is fixed by the binder component, the fiber structure having excellent durability such as physical properties and shape, and the fiber A textile product using the structure is obtained, and its industrial value is extremely large.

  1 to 16: opening having an opening angle of less than 120 degrees

Claims (12)

A fiber structure comprising a main fiber and a binder component, wherein the main fiber is fixed by the binder component,
A fiber structure having two or more openings having an opening angle of less than 120 degrees and a flatness defined by the following formula in the single fiber cross-sectional shape of the main fiber: .
Flatness = (B / A) × 100
A: The longest length in the fiber cross section B: The length in the direction perpendicular to the length direction of A in the fiber cross section   The fiber structure according to claim 1, wherein the single-fiber cross-sectional shape of the main fiber has five or more openings.   The fiber structure according to claim 1 or 2, wherein the main fiber is a hollow fiber. The fiber structure according to any one of claims 1 to 3, wherein a fiber filling rate defined by the following formula is in a range of 30 to 80% in a single fiber cross-sectional shape of the main fiber.
Fiber filling rate (%) = (C / D) × 100
C: area of the fiber cross section D: circumscribed circle area of the fiber cross section   The fiber structure in any one of Claims 1-4 whose single fiber diameter of the said main fiber is in the range of 10-50 micrometers.   The fiber structure according to any one of claims 1 to 5, wherein a fiber length of the main fiber is in a range of 30 to 100 mm.   The fiber structure according to any one of claims 1 to 6, wherein the binder component is a core-sheath binder fiber.   The fiber structure according to any one of claims 1 to 6, wherein the binder component is a non-fibrous resin binder. The fiber structure according to any one of claims 1 to 8, wherein the density of the fiber structure is 0.06 g / cm ³ or less. Basis weight of the fiber structure is in the range of 50~5000g / ^{m 2,} the fiber structure according to any one of claims 1 to 9.   The fiber structure in any one of Claims 1-10 whose thickness of a fiber structure exists in the range of 1-200 mm.   Vehicle material, cushion material, sound absorbing material, bedding, furniture, clothing, filter material, sanitary material, building material, civil engineering material, and agriculture, comprising the fiber structure according to any one of claims 1 to 11. Any textile product selected from the group consisting of materials.